Headlamp

ABSTRACT

A headlight device that can be mounted to a surgical face shield, helmet, or other type of headgear with dual-sided peel and stick adhesive or magnets allowing for various mounting locations.

RELATED APPLICATIONS

This application is a continuation U.S. patent application Ser. No.13/750,270 which was filed with the U.S. Patent and Trademark Office onJan. 25, 2013. This application claims the benefit of U.S. ProvisionalPatent Application Ser. No. 61/590,424 which was filed on Jan. 25, 2012and U.S. Provisional Patent Application Ser. No. 61/700,999 which wasfiled on Sep. 14, 2012, their subject matter incorporated herein byreference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention is directed to a headlight and more particularlyto a removeable headlamp.

2. Description of the Related Art

Surgical headlamps or headlights are known that are mounted to aheadband. These headlamps typically have a remote light source that isconnected to the headlamp via a fiber optic cable. These headlamps areusually adjustable when worn on a user's head so that the headlamp ispositioned at a desired location on the user's head.

Battery powered, headlamps utilizing an incandescent lamp as a lightsource have also been used. Typically, the high power consumption,relatively low light output, high weight, and short battery life of suchdevices have made their use unsatisfactory.

In modern operating rooms and dental offices, doctors, surgeons, nurses,anesthesiologists, technicians, and the like, wear face shields. Theseface shields, interfere with prior art headlamps.

The user is unable to wear both the banded headlamp and the banded faceshield. Further, if the headlamp is configured to attach to a pair ofeye glasses or is integrally formed in an eye glass frame, glare fromthe headlamp on the inside of the face shield can interfere with thewearer's field of view. Additionally, if the headlamp does not have anextremely low profile, the face shield will not sit properly over auser's face and provide the intended protection to the user.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the present invention, a surgicalheadlight is provided that overcomes the problems of headlamps of theprior art.

At least one lamp housing is provided. The lamp housing has fourmounting points and two magnet attach points on the underside arrangedto conform to the contour of the helmet. This or similar sucharrangements help maintain uniform contact across the helmet surface.

In embodiment, the spot size adjuster and the brightness control arecoaxially arranged on the lamp housing and are accessible from allsides.

In one embodiment, the disclosed headlamp is sterile, disposable, anddelivered to a user in a sterile package.

The surgical headlamp can also be mounted to a surgical face shield,helmet, or other type of headgear with dual-sided peel and stickadhesive that allow for various mounting locations.

In one embodiment, coaxially located adjustment features allow for avariety of mounting configurations while maintaining symmetry of accessto controls of the surgical headlamp with either the left or right hand.A light aiming mechanism comprises of a ball pivot with an integrallens. Spot size adjustment is controlled by varying the distance betweena single lens and the LED. A coaxially mounted brightness control isprovided.

The surgical headlamp is energy efficient using pulse width modulationtechnique for brightness control. Batteries preferably provide power.

Other objects and features of the present invention will become apparentfrom the following detailed description considered in conjunction withthe accompanying drawings. It is to be understood, however, that thedrawings are designed solely for purposes of illustration and not as adefinition of the limits of the invention, for which reference should bemade to the appended claims. It should be further understood that thedrawings are not necessarily drawn to scale and that, unless otherwiseindicated, they are merely intended to conceptually illustrate thestructures and procedures described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the headlamp;

FIG. 2 is a top view of the headlamp;

FIG. 3 is a front view of the headlamp;

FIG. 4 is a side view of the headlamp;

FIG. 5 is a back view of the headlamp;

FIGS. 6A and 6B is a cross section of the headlamp;

FIGS. 7A-7C depict a helmet;

FIG. 8 is a schematic depiction of a magnetic mount;

FIG. 9 is the headlamp with the lamp mounted;

FIGS. 10A and 10B are another view of the headlamp of FIG. 9;

FIG. 11 is a headlamp with a combined adhesive and magnetic mount;

FIG. 12 is a top view of a headlamp; and

FIG. 13 is a cross section of the headlamp of FIG. 12.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS

The disclosed surgical headlamp is preferably a self-contained,disposable, LED light, which is battery powered. The headlamp provideson the spot supplemental lighting for surgery. While the surgicalheadlamp can be reused, it is intended to be a single use disposabledevice. Preferably, due to plastic material choice, the headlamp islightweight.

The surgical headlamp features a ball pivot to adjust the focus point oraimpoint of the illuminated field. The surgical headlamp is alsolightweight due to its construction. An on/off switch allows the user toturn the surgical headlamp off when it is not needed. A variablebrightness control allows the user to adjust the brightness as required,which could be a separate control. A discrete brightness control mayalso be integrated with the on/off switch, which provides successivebrightness settings with each push of the button. For example, the firstpush turns the lamp on and sets brightness at 25%, the next push sets itto 50%, the next to 75%, the next to 100%, the next cycles back to off.More or less brightness setting selections may also be provided for.

Given the variety of face shields, the surgical headlamp may provide apeel and stick adhesive for mounting. Finally, the surgical headlamp issterile and ready to use out of the box.

FIG. 1 is a first embodiment of the inventive surgical headlamp 10. Asshown, a single lamp housing 12 is provided. The lamp housing 12 has adirectional aiming portion 14, preferably provided by a ball pivot 16.The aiming portion 14 may include a spot size adjuster 18. Preferably,the spot size adjuster is rotated using integral grips 20. Rotation ofthe spot size adjuster moves lens 22 in an axial direction shown bydouble arrow 24. In one embodiment, the spot size adjustment moves about4-8 mm, which varies the spot size from about 5 inches to about 8 inchesin diameter at two feet distance from the lamp. In one embodiment, thespot size adjustment 18 incorporates a push switch to turn the headlamp10 on and off. In another embodiment, as the spot size adjustment 18 isrotated the headlamp 10 first turns on, then the spot size is adjustedfrom either its maximum or minimum to its other size extreme.

It should be noted that lens 22 is a polycarbonate or PMMA plastic lens.An achromatic glass lens is preferably used to limit chromatic andspherical aberration. In one embodiment, an achromatic doublet is usedas lens 22.

Lamp housing 12 further comprises a variable brightness control. Likethe spot size adjuster 18, the variable brightness control 28 includesgrips 20. In one embodiment, the variable brightness control is coupledto a variable resistor. The variable resistor is part of a pulse widthmodulated (PWM) drive for a light emitting diode (LED) arranged in lamphousing 12. The variable resistor varies the duty cycle of the drivesignal thereby varying the brightness. Alternatively, the variablebrightness control can control an iris, which varies the opening size.

To mount the lamp housing 12 to a surgical faceplate, the lamp housing12 may be provided with wings, which can pivot to accommodate surgicalfaceplates having varying arcs. The lamp housing 12 can be affixed usingpeel and stick tape 30. In one embodiment, the tape 30 is thick enoughto accommodate varying faceplate arcs.

A top view of the surgical headlamp 10 is shown in FIG. 2. As shown, theball pivot 16 is configured to have a greater range in a verticaldirection than a horizontal direction. It should be noted that the lamphousing 12 can be shaped to provide specific travel tracks for the ballpivot 16 or equal movement in all directions.

As is evident from FIG. 3, the components are arranged coaxially or on acenterline as described from the front to the rear of the headlamp. Inthis manner, all of the adjustments can be accessed by either hand andfrom any direction.

In alternative embodiments, the surgical headlamp 10 is mounted usingclips. In one embodiment, the wings 26 are hinged or flexible to moveabout 10°.

In use, a sealed package containing the headlamp 10 is opened. Thepackage is pre-sealed and the headlamp 10 is a sterile device. In apreferred embodiment, the headlamp 10 is manufactured from componentsthat can be sterilized using gamma radiation. In one embodiment, theheadlamp 10 is removed from its sterile package, coverings from adhesivepads 30 located on the mounting wings are removed. The headlamp 10 ispositioned on a face shield and installed. The user then pushes the lensassembly to turn on the headlamp 10 and pushes the lens assembly againto turn off headlamp 10.

The lens housing, which is the spot size adjuster 18, serves as a beamdirector and on/off switch. By avoiding a separate switch, this headlamp10 can be activated by a finger or by pressing, for example, with theback of a hand or wrist. Once on, the headlamp 10 can be pointed to adesired position. The spot size control 18 can be rotated to the desiredsize and the brightness control 28 can be rotated to achieve the desiredbrightness. After use, headlamp 10 can be disposed of.

In non-sterile environments, and for non-sterile requirements, theheadlamp 10 can be reused. In one embodiment, the headlamp 10 isreturned for reconditioning including replacing used batteries andundergoing gamma radiation and sterile packaging. While disclosed as asterile surgical headlamp. The present headlamp can be used in anyapplication when a head-mounted light is required.

In one embodiment, multiple LEDs are provided in a single lamp housing12. In one embodiment, stereo illumination is provided.

In one embodiment, a magnetic attachment method replaces the peel andstick mounting method. The magnetic mounting method is preferred formounting the headlamp device to a surgical helmet covered with a clothmaterial.

As shown schematically in FIG. 8, one or more magnets 82 are locatedinternally to the headlamp, and one or more magnets 84, which arelocated inside a helmet, attract each other allowing for secureattachment of the headlamp to the helmet. It should be noted that thehelmet can be a strap, hood, or the like.

The helmet, to which the headlamp is mounted, has an inner shell 86 andouter shell 88. The gap between the shells allows for insertion of asecond set of magnets in between them by a plastic magnet carrier 83.Once inserted in the gap between the inner shell 86 and the outer shell88, the magnets 84 are not visible to the user.

The location of the magnets 84 in the magnet carrier 83 that is insertedinto the helmet and the magnets 82 internal to the headlamp are designedto be coaxially aligned so as to position each respective magnet setover the other set to maximize the alignment of magnetic fields formaximum attraction. Once the headlamp is positioned over the magnetsinternal to the helmet, the magnetic fields naturally align and attract,attaching the headlamp securely to the helmet. In one embodiment, asteel shield is used to help focus the magnetic fields of the respectivehelmet and headlamp magnets in such as manner to maximize magneticcoupling.

In one embodiment, the headlamp has magnets arranged on an underside ofthe headlamp assembly. A magnet bracket adapted to fit in a helmet isshown. In one embodiment, ridges are provided to hold the magnet bracketbetween an inner and outer shell of the helmet. In one embodiment, themagnet bracket has aligning elements for aligning the headlamp andbracket.

As shown, magnets are under the plastic housing of the headlamp. In oneembodiment, the housing is injection molded with the magnets. In anotherembodiment, the magnets are arranged inside the housing.

In one embodiment, the magnets are affixed to an outside surface of thehousing using an adhesive. In this embodiment, a user can choose betweenan adhesive mount and/or a magnetic mount.

FIG. 9 is a helmet with the lamp mounted thereon. FIG. 10 is anotherview of the headlamp mounted to a helmet.

FIG. 11 is another embodiment of the headlamp. An adhesive mount isprovided so that the headlamp can be mounted to virtually any surface.The adhesive mount is contoured to mate with the headlamp. Due to thecontouring, the headlamp is limited in its lateral movement. Theheadlamp and the adhesive mount preferably have matching magneticmounting elements.

FIG. 12 is another embodiment of surgical headlamp 100. As shown asingle lamp housing 120 is provided. The lamp housing 120 has adirectional aiming portion preferably provided by a ball pivot 160. Theaiming portion includes a spot size adjuster 180. Preferably, the spotsize adjuster is rotated using grips 200. Rotation of the spot sizeadjuster moves lens 220 in an axial direction. In a preferredembodiment, the spot sized moves about 4-8 mm, which varies the spotsize from about 5 inches to about 8 inches at two feet. In oneembodiment, the spot size adjustment 180 is a push switch to turn theheadlamp 100 on and off. In another embodiment, as the spot sizeadjustment 180 is rotated the headlamp 100 first turns on, then the spotsize is adjusted from either its maximum or minimum to its other sizeextreme.

It should be noted that lens 220 is preferably a polycarbonate lens. Anachromatic lens is preferably used to limit chromatic and sphericalaberration. In one embodiment, an achromatic doublet is used as lens220.

Lamp housing 120 further comprises a variable brightness control 280.Like the spot size adjuster 180, the variable brightness control 280includes grips 200. In a preferred embodiment, the variable brightnesscontrol is coupled to a variable resistor. The variable resistor is partof a pulse width modulated (PWM) drive for a light emitting diode (LED)arranged in lamp housing 120. The variable resistor varies the dutycycle of the drive signal thereby varying the brightness. Alternatively,the variable brightness control 280 can control an iris.

To mount the lamp housing 120 to a surgical face plate, the lamp housing120 is provided with wings 260. In a preferred embodiment, the wings 260can pivot to accommodate surgical face plates having varying arcs. Thelamp housing 120 is affixed using peel and stick tape 300. In oneembodiment, the tape 300 is thick enough to accommodate varying faceplate arcs. Preferably, the components are arranged coaxially. In thismanner, all of the adjustments can be accessed by either hand and fromany direction.

FIG. 13 is a cross section of the surgical headlamp 100. As shown, coinbatteries 400 are preferably arranged in the mounting wings 260. Thecoin batteries 400 are coupled to PC board 420 which includes thepotentiometer 440 for the PWM circuit discussed above. As shown, when aforce is applied to the spot size adjuster 180, the entire assembly isable to move towards the mounting wings 260 guided in area 500. Thismovement depresses a switch 460 to turn LED 48 on and off.

In alternative embodiments, the surgical headlamp 10, 100 is mountedusing clips. In one embodiment, the wings are hinged or flexible to moveabout 10°.

In one embodiment, the housing containing the magnets is affixed to theoutside of the surgical helmet with an adhesive mount. The geometry ofthe mount and of the matching underside of the headlamp is such that inorder to remove the headlamp, the user must pull the headlamp away fromthe mount along the axis of magnetic attraction thus preventinginadvertent removal by sliding the headlamp sideways.

Thus, while there have shown and described and pointed out fundamentalnovel features of the invention as applied to a preferred embodimentthereof, it will be understood that various omissions and substitutionsand changes in the form and details of the devices illustrated, and intheir operation, may be made by those skilled in the art withoutdeparting from the spirit of the invention. For example, it is expresslyintended that all combinations of those elements and/or method stepswhich perform substantially the same function in substantially the sameway to achieve the same results are within the scope of the invention.Moreover, it should be recognized that structures and/or elements and/ormethod steps shown and/or described in connection with any disclosedform or embodiment of the invention may be incorporated in any otherdisclosed or described or suggested form or embodiment as a generalmatter of design choice. It is the intention, therefore, to be limitedonly as indicated by the scope of the claims appended hereto.

What is claimed is:
 1. A sterilizable lighting device, comprising: aheadgear device having an outer shell and a plurality of magneticmounting elements disposed below the outer shell and spaced apart fromone another in a plurality of locations; a headlight device comprising:a housing, a magnetic mounting portion coupled to the housing comprisinga magnet, a lens assembly coupled to the housing, wherein the lensassembly comprises at least one lens and a ball pivot aiming mechanism,the ball pivot aiming mechanism comprising a ball pivot, a light sourceat least partially coaxially aligned with the at least one lens insidethe ball pivot, wherein the light source comprises at least one LEDarranged directly adjacent to the at least one lens and configured toproject light through the at least one lens, and a switch for the lightsource; wherein the magnetic mounting portion is configured tomagnetically couple to the plurality of magnetic mounting elements, theheadlight device is mountable in each of the plurality of locations, andthe plurality of magnetic mounting elements are arranged in the headgeardevice such that the headlight device is arrangeable to be mounted in aplurality of locations.
 2. The sterilizable lighting device of claim 1,wherein the magnets are at least one of embedded in the housing orattached to the housing.
 3. The sterilizable lighting device of claim 2,further comprising an external mount configured to magnetically retainthe housing, wherein the housing is configured to be separated from theexternal mount by pulling the headlamp away along an axis of magneticattraction.
 4. The sterilizable lighting device of claim 1, wherein thelighting device is sterile.
 5. The sterilizable lighting device of claim1, wherein the at least one LED is driven by a pulse width modulateddriver circuit.
 6. The sterilizable lighting device of claim 1, whereinthe light aiming mechanism further comprises an integral on/off switch.7. The sterilizable lighting device of claim 6, wherein the on/offswitch is a push switch.
 8. The sterilizable lighting device of claim 1,wherein the ball pivot has integral coaxial beam spot size adjustment,wherein spot size adjustment is controlled by varying a distance betweenthe lens assembly and the light source.
 9. The sterilizable lightingdevice of claim 8, further comprising a coaxially mounted brightnesscontrol mounted to the lens assembly.
 10. The sterilizable lightingdevice of claim 1, wherein the lens assembly comprises one or more of apolycarbonate lens, a PMNA plastic lens, an achromatic glass lens, andan achromatic doublet.
 11. A sterilizable lighting device, comprising: aheadgear device having an outer shell and a plurality of magneticmounting elements disposed below the outer shell and spaced apart fromone another in a plurality of locations; a headlight device comprising:a housing, a magnetic mounting portion coupled to the housing comprisinga magnet, a lens assembly coupled to the housing, wherein the lensassembly comprises a ball pivot aiming mechanism, the ball pivot aimingmechanism comprising a ball pivot, a light source at least partiallycoaxially aligned with the at least one lens inside the ball pivot,wherein the light source comprises at least one LED arranged adjacent toa lens of the lens assembly and configured to project light through thelens assembly and the ball pivot that illuminates a field, and a switchfor the light source; wherein the magnetic mounting portion isconfigured to magnetically couple to the plurality of magnetic mountingelements, the headlight device is mountable in each of the plurality oflocations, and the plurality of magnetic mounting elements arranged inthe headgear device provide a plurality of mounting locations formounting the headlight device.
 12. The sterilizable lighting device ofclaim 11, wherein the light source is arranged at least partially insidelens assembly.
 13. A sterilizable lighting assembly, comprising: asterile headgear comprising an outer shell and a plurality of magneticmounting elements disposed below the outer shell; a face shield affixedto the sterile headgear; and a headlight device configured to be mountedto the headgear comprising: a housing comprising a sterilizeable plastichaving a magnetic mounting portion containing a magnet, a lens assemblycoupled to the housing, wherein the lens assembly comprises at least onelens and a ball pivot aiming mechanism, the ball pivot aiming mechanismcomprising a ball pivot, a light source at least partially coaxiallyaligned with the at least one lens inside the ball pivot and arrangeddirectly adjacent to the at least one lens and configured to projectlight through the at least one lens, and a switch for the light source;wherein the magnetic mounting portion of the headlight is configured tomagnetically couple to the plurality of magnetic mounting elements ofthe headgear device with a barrier of the face shield disposedtherebetween, the headlight device is mountable in each of the pluralityof locations, and the plurality of magnetic mounting elements provide aplurality of mounting locations such that the headlight device isconfigured to mount to the headgear device at a plurality of locations.